Box folding apparatus



June 19, 1962 o. P. WELSH 3,039,369

BOX FOLDING APPARATUS Filed March 23, 1960 3 Sheets-Sheet 1 June 19,1962 o. P. WELSH 3,039,369

BOX FOLDING APPARATUS Filed March 23, 1960 3 Sheets-Sheet 2 INVENTORv 0777207246 Z/Zlsfb f, mm sees t Q Q Q 0. P. WELSH June 19, 1962 BOX FOLDING APPARATUS F iled March 23, 1960 5 SheetsSheet 3 xx E Wmw Nm wm UnitedStates Patent 3,039,369 BOX FOLDING APPARATUS Ormonde P. Welsh, 311Portland Ave. Minneapolis, Minn. Filed Mar. 23, 1960, Ser. No. 17,089Claims. (CI. 9349) The present invention relates to a novel apparatusfor folding box blanks, and more particularly to a novel apparatus forfolding knocked down or collapsible type boxes so that the folded blankis substantially flat to facilitate shipping and storing.

In my United States Patent 2,911,889, there is disclosed and claimed anapparatus for folding knocked down or collapsible type box blanks to aflattened condition, which apparatus represents a substantial advance inthe box blank folding art. An object of the present invention is toprovide an improvement in an apparatus of the type disclosed in theabove mentioned patent.

A more specific object of the present invention is to provide a novelapparatus of the above described type with materially simplified meansfor accomplishing folding of trailing flaps of successive blanks whilethe blanks are continuously moving at high speeds. A further object ofthe present invention is to provide blank flap folding means which maybe used in an apparatus of the above described type or with variousother apparatus, which means is constructed so that a single element isadapted to fold a trailing flap of a blank forwardly and over a leadingportion of the blank, or in other words, the folding means is adapted tofold the trailing flap about 180 degrees while the blank is continuouslymoving at a high speed.

Other objects and advantages of the present invention will becomeapparent from the following description and the accompanying drawingswherein:

FIG. 1 is a fragmentary plan view showing a portion of an apparatusincorporating the features of the present invention;

FIG. 2 is a longitudinal sectional view taken generally along line 22 inFIG. 1;

FIG. 3 is an enlarged fragmentary partial sectional view taken generallyalong line 33 in FIG. 1;

FIG. 4 is a fragmentary cross sectional view taken along line 44 in FIG.3;

FIGS. 5 through 8 are plan views respectively showing successive stepsin the folding of a trailing flap of a blank over the body of the blankby the apparatus of the present invention;

FIGS. 9 through 12 are simplified vertical sectional views respectivelycorresponding to FIGS. 5 through 8;

FIG. 13 is a perspective view showing a blank of the type adapted to befolded by the apparatus of the present invention; and

FIG. 14 is a perspective view showing a fully folded blank.

As will be understood, apparatus incorporating features of the presentinvention may be adapted for processing various box structures, and theapparatus shown for the purpose of illustrating the present invention isespecially suitable for folding box blanks 20 shown best in FIGS. 13 and14. Each blank 29 comprises a central bottom panel 22 and opposite sidepanels or flaps 24 and 26 articulated to the bottom panel along scoredbend lines 28 and 30, respectively. The blank is provided with oppositeend panels or flaps 32 and 34 which are articulated to the bottom panelalong scored bend lines 36 and 38. In order to connect the ends and thesides of the box blanks in a manner to permit clamping thereof, thesides are provided with diagonal scored bend lines 44 42 and 44-46, andthe end sections 32 and '34 are respectively provided with flaps 48-56}and 52-54 joined thereto Bfififibfi Patented. June 155, 1962 "ice alongscored bend lines 56, 5'8, 60 and 62, respectively. When folding theflat blank in the condition shown in FIG. 13 to the fully foldedcondition shown in FIG. 14, the sides are first folded over andsubstantially against the bottom section 22 and corner portions 64, 66,68 and 7 ii of the sides are reversely bent along the diagonal bendlines. The end flaps 48-50 and 5254 are then bent over the end sectionsand patches of glue are applied thereto whereupon the end sections arebent over the bottom panel as shown in FIG. 14 so that the glued flapsare pressed against the folded corner portions of the sides. Thespecific structure of the box blank 20 is Well known and forms no partof the present invention.

An apparatus 8% which is shown, in part, in FIGS. 1 and 2 is providedfor folding a plurality of successive blanks in the manner describedabove. The apparatus bit is substantially identical to the apparatusdisclosed in the above mentioned co-pending application except for themeans generally designated by the numerals 82 and 84 and adapted to foldtrailing sections of the blanks. Therefore, reference is hereby made tothe above mentioned co-pending application for a disclosure of portionsof the apparatus not shown in the drawings of this application and alsofor a more complete disclosure of portions of the apparatus shown hereinbut only briefly described.

The apparatus 89 is provided with sheet feeding means genermlydesignated by the numeral 86 for feeding successive blanks to a timingsection 88 of the apparatus at which there is provided timing chainmeans 90' which carries dogs 92 for positively engaging and advancingsuccessive blanks received from the feeding means. It is to be notedthat the blanks are arranged and fed into the apparatus so that one oftheir side flaps, for example, the side flap 2.6 is in a leadingposition and the other side 24 is in a trailing position and the endsections 32 and 34 are arranged at opposite sides of the path of travelof the blanks. The blanks are successively delivered from the timingsection to a first folding section of the apparatus generally designatedby the numeral 94 in which the trailing sides 24 are folded and then theleading sides 26 are folded. More specifically, the folding section 94is pro- '-vided with pairs of cooperable upper and lower endless belts96 and 98 disposed adjacent opposite margins of the path of travel ofthe blanks as shown in FIG. 1 so as to tend around pulleys 100 and 102respectively mounted on shafts 104 and 106, and the belts 5 8 aresimilarly mounted on pulleys 168 and secured to rotatable shafts 112 and114. The shafts 112 and 104 are driven from a rotatable shaft 116through suitable gear means 113, and the shaft 116 is, in turn, drivenfrom drive shaft means 120 extending along the side of the apparatus bycooper-able bevel gears 122 and 124. The shafts 114 and 1% are similarlydriven from a shaft 126 by suitable gear means generally designated bythe numeral 128, which shaft 126 is also driven from the drive shaftmeans 124 by beveled gears 1 3i and 132.

The blanks entering the folding section 94 of the apparatus and beingconveyed by the endless. belts 96 and rotatable finger means beneath theblanks for partially folding the trailing flaps or sides of the blanks,and additional rotatable finger means above the blanks for finishing thefolding operation. In accordance with the present invention, thispreviously suggested folding means has been greatly simplified in thatthe second mentioned or upper rotatable finger means has been completelyeliminated along with the necessary drive mechanism therefor while atthe same time the apparatus is constructed so that it will accomplishthe folding operation previously performed by such upper rotatablefinger means.

The folding means 82 comprises pairs of oppositely extending foldingmembers or fingers 134 and 136 mounted on a rotatable hollow shaft 138and disposed for engaging the trailing edges of the blanks. Majorportions of these fingers extend radially from the shaft 1'33, but it isimportant to note that the fingers respectively include short endportions 140 and 142 which project forwardly in the direction ofrotation of the shaft 163 and at substantially right angles to the majorportions of the fingers. These end or hook portions function to completethe folding of the trailing flaps against the blank bodies in the mannerdescribed fully below. The hollow shaft 138 is driven at a speed whichvaries during each rotation thereof so that the fingers, whenapproaching a blank trailing edge, will be accelerated suificiently toengage and fold the trailing blank portion and decelerated suflicientlyto become disengaged from the blanks. More specifically, a shaft 144extends through and is rotatably mounted within the hollow shaft 138,which shaft carries a gear 146 secured to one end thereof. The gear 146-and thus the shaft 144 are driven from a gear 148 fixed on a shaft 150which also carries a sprocket Wheel 152 and is driven by a drive chain154. The chain 154 is driven from a sprocket 156 on the shaft 126 andserves also to drive other portions of the apparatus as mentioned below.

As shown best in FIGS. 1, 3, and 4, a beveled gear 158 is keyed orotherwise secured to an end of the shaft 144 opposite from the gear 146.A similar but oppositely disposed beveled gear 160 is keyed or otherwisesecured "to the adjacent end of the hollow shaft 138, and a cage member162 which is freely disposed on the shaft 144 and carries a pair ofoppositely disposed beveled gears 164 and 166 on stub shafts 168 and178*, respectively. The beveled gears 164 and 166 mesh with and providea driving connection between the gears 15% and 160. An arm 172 is{formed integral with or connected to the cage member 162 and has itsouter end pivotally connected to a rod .174, by pin means 176. Anopposite end of the rod 174 is pivotally connected to a disk 1'78 fixedon the shaft 112 by eccentrically disposed pin means 180 so that as thedisk 178 is rotated, the cage member 162 is oscillated. The pin means180 is adjustable along a radial slot 182 in the disk 173 so that theoscillating movement of the cage member may be adjusted.

FIGS. through 12 illustrate the manner in which the apparatus functionsto fold the trailing side 24 of a continuously moving blank. In FIGS. 5and 9, the blank has been advanced to a position over the hollow shaft138 and the folding finger 134 is approaching but slightly spaced behindthe trailing edge of the blank. The folding finger is then acceleratedrelative to the blank and in the direction of movement of the blank andthis is accomplished by timing the drive means of the apparatus so thatthe cage member 152 is moved in a counterclockwise direction as viewedin FIGS. 2 and 3 with the result that the clockwise speed of the gear161 and thus the folding fingers is increased. in addition, furtheracceleration is obtained by the inherent increase of the component ofmovement of the finger 134 in the direction of movement of the blanks asthe finger approaches the vertical position. The accelerating finger 134engages the trailing edge of the side flap 24 and initially folds theside through an arc of about 90 degrees to an upright position as shownin FIGS. 6 and 10. It is to be noted that at the same time the blank ispassed beneath fixed direction of movement of the blank is retarded butis still suificient to enable the finger 134 to fold the side 24forwardly and over the body portion 22 as the trailing edge or bend line28 of the blank advances sufficiently to avoid interference with thefolded finger. Then as the blank and folding finger approach thepositions shown in FIGS. 8 and 12, the folding finger is relativelyrapidly retarded, and this is accomplished by timing the drivingmechanism so that the cage member 16 2 is moved in a clockwise directionas viewed in FIGS. 2 and 3. Movement of the finger 134 is retardedsufficiently so that it will not unduly interfere with or pull down onthe blank, but at the same time the movement of the finger 134 is suchthat the forwardly projecting end or hook portion 14% thereof engagesthe blank side portion 24 and folds it down against the body portion 2 2after which the blank is advanced from beneath the folding finger. Ithas been found that the beveled gear differential means enables agreater variation in the speed of the folding fingers to be obtainedthan the corresponding differential means disclosed in the abovementioned application, and this greater speed variation enables thefolding fingers to be utilized for folding the trailing sides of theblanks through arcs of about degrees in the manner described above.

The leading portions or sides of the blanks are folded by meansgenerally designated by the numeral 188 and including a pair of foldingmembers 190 mounted on a rotatable shaft 192,. Each of the foldingmembers includes a pair of oppositely extending arms 1% and 196respectively having arcuate end portions 198 and 21)!) extending in adirection opposite to the direction of rotation thereof. These arms areproportioned and driven so that the end portions thereof extend beneaththe path of travel of the blanks, which blanks are advanced along theirpath of travel at a rate in excess of the rate of movement of therotating arms along the path of travel whereby the leading portions ofsuccessive blanks are engaged by the arcuate finger portions 198 and 2%of the arms and folded upwardly about 90. Complete folding of theleading sides of the blanks is obtained by providing a pair of fixedelongated folding bars not shown. The diagonal corner portions of theleading blank sides are folded by elongated folding bars, not shown,similar to the above mentioned bars 184- and 186. The trailing sides ofthe blanks are retained in a folded condition by hold down members 2%mounted on an oscillating shaft 294 while the forward portions of theblanks are being folded. The oscillating shaft is operated so that thehold down members 2492 are withdrawn to permit folding of the leadingblank sides and then advanced downwardly to hold the folded trailingsides of the blanks. If desired, a member 2% mounted on a rotatableshaft 2% may be provided beneath the path of travel of the blanks, andarranged so that lifting block portions 21% thereof will engage andinitially slightly lift the leading edge of a blank prior to engagementof the balnk with one of the folding arms. The shafts 192 and 208 areprovided with sprocket wheels thereon which are engaged and driven bythe chain 154.

The blanks having their leading and trailing sides folded in the mannerdescribed above are advanced to another section of the apparatus inwhich the leading and trailing flaps 5li54 and 4352 of the oppositeblank end sections are folded over and against their respective endsections. As-shown in FIGS. 1 and Z'this section of the apparatusincludes the above mentioned folding means 84 which is identical to theabove described folding means 82 with the exception that folding fingers212 thereof are disposed for engaging the trailing end flaps 48 and 52rather than the trailing side portions of a blank. Since the foldingmeans 84 is identical to the folding means 82, it need not be describedin detail and it suffices to state that the folding fingers 212 aremounted on a rotatable hollow shaft 214 which is driven at variablespeeds by differential means 216 identical to the differential gearmeans described above. The blanks leaving the folding means 84 arefurther processed in the manner and by the means briefly mentioned aboveand fully disclosed in the above mentioned co-pending application, andsince the remaining portions of the apparatus form no part of thepresent invention, they will not be further described herein.

While the preferred embodiment of the present invention has been shownand described herein, it is obvious that many structural details may bechanged without departing from the spirit and scope of the appendedclaims.

The invention is claimed as follows:

1. An apparatus for folding a trailing portion of a blank movingcontinuously along a predetermined path of travel forwardly andsubstantially against one side of a leading section of the blank,comprising folding means rotatable about an axis disposed at a side ofsaid path of travel opposite from said one side for engaging and foldingsaid blank portion, and means for moving said blank and said foldingmeans at predetermined variable relative lineal speeds along said pathof travel so that said folding means is successively relatively advancedand retarded with respect to the blank to accomplish folding of saidblank portion, said folding means comprising a generally radiallyextending portion projecting for traversing said path of travel forinitially engaging and folding said blank portion forwardly over saidblank section, and said folding means including an outer end portionprojecting forwardly of said radially extending portion for engaging andfolding a partially folded blank portion substantially against the blanksection.

2. An apparatus for folding a trailing portion of a blank movingcontinuously along a predetermined path of travel forwardly over andsubstantially against one side of a leading section of the blank,comprising folding means rotatable about an axis disposed at a side ofsaid path of travel opposite from said one side for engaging and foldingsaid blank portion, and drive means including a differential gearassembly and means for periodically actuating said differential gearassembly for driving said folding means at predetermined variable linealspeeds so that said folding means is successively advanced and retardedalong said path of travel with respect to a blank to accomplish foldingof said blank portion, said folding means comprising a generallyradially extending portion projecting for traversing said path of travelfor initially engaging and folding said blank portion, and said foldingmeans including an outer end portion projecting forwardly of saidradially extending portion for engaging and folding said blank portionsubstantially against said blank section.

3. An apparatus for folding a trailing portion of a blank movingcontinuously along a predetermined path of travel forwardly and over oneside of a leading section of the blank, comprising folding meansrotatable about an axis disposed at a side of said path of travelopposite from said one side for engaging and folding said blank portion,and drive means connected with said folding means for moving saidfolding means at predetermined variable lineal speeds along said path oftravel so that said folding means is successively advanced and retardedwith respect to the blank to accomplish folding of said blank portion,said drive means comprising opposing axially aligned driving and drivenbeveled gears, a cage member pivotally disposed between said gears,beveled gear means rotatably mounted on said cage memher and meshingwith both of said beveled gears, and means for oscillating said cagemember, said folding means comprising a generally radially extendingportion projecting for traversing said path of travel for initiallyengaging and folding said blank portion, and said folding meansincluding an outer end portion projecting forwardly of said radiallyextending portion for engaging and further folding said blank portion.

4. An apparatus for folding a trailing portion of a blank movingcontinuously along a predetermined path of travel forwardly and over oneside of a leading section of the blank, comprising folding arm meansrotata ble about and extending generally radially from an axis disposedat a side of said path of travel opposite from said one side forengaging and folding said blank portion, said arm means projecting fromsaid axis for traversing said path of travel, and drive means for movingsaid folding arm means at predetermined variable lineal speeds alongsaid path of travel so that said folding arm means is successivelyadvanced and retarded with respect to the blank to accomplish folding ofthe blank portion,

said drive means including a driven beveled gear connected with saidrotatable anm means, an oppositely disposed axially aligned drivebeveled gear, a cage member pivotally disposed between said gears,beveled gear means mounted on said cage member for rotation about anaxis extending radially with respect to said first mentioned axis andmeshing with both of said gears, and means for oscillating said cagemember.

5. An apparatus for folding a trailing portion of a blank movingcontinuously along a predetermined path of travel forwardly and over oneside of a leading section of the blank, comprising folding meansrotatable about an axis disposed at one side of said path of travel andincluding a pair of oppositely disposed radially extending armsprojecting for traversing said path of travel for initially engagingtrailing edges of successive blanks moving along said path of travel,each of said arms having an end portion projecting forwardly therefromfor subsequently engaging trailing portions of successive blanks andfurther folding said trailing portions, means including a rotatableshaft supporting said folding means, a beveled gear fixed on said shaft,a second rotatably supported and driven beveled gear oppositely disposedwith respect to and axially aligned with said first mentioned gear, acage member pivotally mounted adjacent said gears for movement about theaxis of said gears, beveled gear means rotatably mounted on said cagemember and disposed between and meshing with both of said gears, andmeans for oscillating said cage member and the beveled gear meanscarried thereby for driving said folding means at predetermined variablelineal speeds along said path of travel so that said arms aresuccessively relatively advanced and retarded with respect to successiveblanks to accomplish folding of said blank portions.

References Cited in the file of this patent UNITED STATES PATENTS2,399,685 McCoy May 7, 1946 2,574,916 Gordon Nov. 13, 1951 2,911,889Welsh Nov. 10, 1959

